In the cosmetic and pharmaceutical sectors, optimal product preservation is a crucial element to ensure the integrity, chemical-physical stability and efficacy of the formulation over time. Airless bottles are an advanced packaging solution in which the product is protected from external contamination, minimizing contact with air and preventing oxidation of the active ingredients.
This technology, which is also increasingly popular in the skincare and dermocosmetics sector, makes it possible to reduce the addition of preservatives and is particularly suitable for delicate formulations – such as serums, anti-aging creams, foundations and lotions – which require a controlled oxygen environment to preserve stability and functional properties. In addition, the possibility of having airless bottles in the refillable version represents a sustainable solution, in line with recent trends in the sector.
How do airless bottles work?
Airless systems for cosmetics are based on two main technologies: piston or flexible pouch. In both cases, there is no suction straw and the delivery is more controlled and homogeneous. In addition, the internal environment remains in vacuum or otherwise sealed, preventing air from mixing with the formula, preserving its freshness and effectiveness.
Airless system components and operation
An airless bottle consists of:
- Airless container/tank: the product is enclosed in a system free from contact with air, so as to reduce microbial contamination and oxidation;
- Piston or diaphragm dispenser: the pump creates an internal pressure that pushes the product upwards without the need for a suction tube;
- Ascent mechanism: depending on the technology used, two types are distinguished:
- Piston system: A sealed piston, located at the base of the container, rises progressively each time the product is dispensed. This configuration offers precise dispensing, reducing waste;
- Flexible bag system: the formula is contained in an inner bag that gradually compresses with the pressure of the pump, preventing air from entering and ensuring full use of the contents.
Thanks to these measures, airless bottles optimize the yield of the formula and extend the shelf-life of cosmetics.
The advantages of airless technology
The use of airless bottles represents a high-performance solution to enhance any type of formula, from emulsifiers (creams, lotions, dense serums) to fluid solutions.
1. Longer product life
The absence of air inside the bottle allows the properties of the cosmetic and its fragrance to be kept intact because it reduces the risk of oxidation and deterioration of the active ingredients. As a result, it increases the stability of the product.
2. Reduction of preservatives
Thanks to the protection from contact with external agents, many cosmetics formulated for airless packaging can benefit from a lower use of chemical preservatives. The formulations are “cleaner” and more delicate, suitable for consumers with sensitive skin or prone to allergies.
3. Less waste and full use of the product
Controlled dispensing allows the formula to be dosed precisely, optimizing consumption and avoiding waste. In addition, by virtue of the piston mechanism or the flexible bag, the airless system allows the container to be almost completely emptied without residue.
4. Increased hygiene and safety
With airless dispensing, the formula does not come into contact with either the air or the external environment. This reduces the risk of microbial contamination, thus improving hygiene and safety of use throughout the product’s life cycle.
5. Modern design, stylish, eco-friendly
Many airless bottles boast a refined aesthetic, with ergonomic shapes and high-quality materials: in some cases plastic (PP, PETG, HDPE), in others with a glass body with a premium look. The design can be customized with surface finishes and treatments that meet the highest branding requirements. The trend towards the use of recyclable materials, such as mono-material plastic or glass, and the availability of refill versions, increase the eco-friendliness of the entire set.
Materials and applications of airless bottles
Airless bottles and their dispensers can be made of different materials depending on the technical specifications and brand image:
- Plastic (PP, PETG, HDPE, etc.): light, resistant and often recyclable;
- Glass: heavier and with a fine aesthetic, ideal for luxury cosmetic lines.
The main applications focus on the cosmetics and skincare sector:
- Moisturizing and anti-aging creams
- Concentrated serums
- Foundation and BB cream
- Sun and dermatological treatments
They are particularly ideal for preserving the properties of organic and natural formulations, formulated with few preservatives and particularly sensitive to contamination with the outside. In addition, thanks to their high protection, airless bottles are also used in the pharmaceutical sector for the storage of gels, ophthalmic solutions and preparations for topical use, ensuring safety and sterility.
Sustainability and innovation in airless packaging
The growing focus on sustainability has prompted many companies to experiment with solutions in recyclable materials (PP, PET, glass) and refill configurations, where the outer part of the bottle (often made of glass or premium plastic) can be reused several times, replacing only the internal tank. Such strategies significantly reduce the amount of waste generated and support the circular economy.
Airless refill bottles: advantages and features
In addition to traditional airless technologies (piston or pouch), there are refill models in which the internal pumping mechanism and the bottle-tank can be replaced, while the outer casing remains the same.
- Double container structure: a valuable outer body (in glass, PETG or PP) and an inner body that acts as a refillable tank;
- Piston system: particularly suitable for viscous or dense formulas, thanks to the excellent return index, minimizing waste;
- Environmental benefits: the waste of resources is limited, since the heaviest (and often most elaborate) part is preserved, while only the light plastic “refill” is replaced;
- Hygiene and protection: the airless mechanism continues to guarantee an optimal barrier against air and bacteria even in refill systems, preserving the characteristics of the product.
According to comparative analyses conducted in Eurovetrocap’s Zero In•Pack Laboratory, the adoption of airless refill systems can reduce the average environmental impact by more than 70%, contributing in a concrete way to the brand’s green positioning.
How to choose the right airless bottle?
When selecting an airless bottle, it’s important to consider a few key factors:
- Product type: choose the material and capacity according to the viscosity and sensitivity of the formulation;
- Design and aesthetics: a bottle with fine finishes improves the perception of the brand;
- Sustainability: opt for materials with reduced environmental impact or rechargeable solutions;
- Dispensing accuracy: Verify pump quality to ensure consistent, waste-free dispensing.
Eurovetrocap airless bottles
Our airless bottles with an elegant and innovative design are the future of cosmetic and pharmaceutical packaging. The available lines – such as Nina or Pamela bottles (15, 30 and 50ml) or the 30 ml Refill airless glass container from the eco collection – offer advanced protection of the formulations, ensuring high hygiene and maximum waste reduction. Perfect for skincare and makeup cosmetics, they ensure premium aesthetics and residue-proof dispensing.
Thanks to their ability to preserve active ingredients and enhance the user experience, Eurovetrocap airless bottles are confirmed as a high-profile solution for brands wishing to consolidate the perception of quality and reliability, while focusing on innovation and sustainability.
If you want to learn more about airless solutions or discover our refill range, contact us: our experts will help you identify the most suitable packaging, combining performance, design and environmental responsibility.
